Casing and Method for Assembling Casing for Water Heater Appliance

ABSTRACT

Casings for water heater appliance and methods for assembling such casings are provided. In one embodiment, a casing includes a wrapper extending generally along a vertical direction between a top edge and a bottom edge, the wrapper including an inner surface and an outer surface and defining an interior of the casing. The casing further includes a channel defined in the outer surface of the wrapper and extending generally peripherally about the wrapper adjacent to one of the top edge or the bottom edge. The casing further includes a cover coupled to the wrapper at one of the top edge or the bottom edge, the cover including a sidewall, the sidewall generally surrounding the channel. The casing further includes a fastener extending through the sidewall and the channel, the fastener coupling the wrapper and the cover together.

FIELD OF THE INVENTION

The present subject matter relates generally to water heater appliances, and more particularly to casings and methods for assembling casings for water heater appliances.

BACKGROUND OF THE INVENTION

Water heater appliances are utilized to heat water for a variety of purposes. In many cases, water heater appliances include a tank. Heating elements, such as gas burners, electric resistance elements, or induction elements, heat water within the tank during operation of such water heater appliances. In particular, the heating elements generally heat water within the tank to a predetermined temperature. The predetermined temperature is generally selected such that heated water within the tank is suitable for showering, washing hands, etc.

Many water heater appliances further include a casing that generally surrounds the tank. The casing can serve to facilitate insulation of the tank (by encasing insulation, such as foam insulation, that surrounds the tank, and can further serve to protect the tank and prevent injury from user contact with the tank. A casing may include a generally tubular wrapper and top and bottom covers. The covers may be coupled to the top and bottom edges of the wrapper to form the casing. The tank may be provided within the interior of the casing.

One issue experienced by casings assembled from a wrapper and top and bottom covers is misalignments between the various components. For example, the top cover and/or bottom cover can be misaligned with the wrapper during assembly. This misalignment can have negative effects for the assembled casing. For example, a misalignment can cause various surfaces of the components to be compromised during use. The thickness of sealing materials utilized between the components can be inconsistent due to such misalignments, leading to inefficiencies and performance losses. A misalignment can cause further misalignments with other water heater appliance components or external components, such as inlet and outlet pipes. The height and appearance of the water heater appliance can be inconsistent due to such misalignment.

Accordingly, improved casings and methods for assembling casings for water heater appliances are desired in the art. In particular, casings and methods which facilitate improved casing component alignment would be advantageous.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with one embodiment, a water heater appliance is provided. The water heater appliance includes a tank defining a chamber, and a casing generally surrounding the tank. The casing includes a wrapper extending generally along a vertical direction between a top edge and a bottom edge, the wrapper including an inner surface and an outer surface and defining an interior of the casing. The casing further includes a channel defined in the outer surface of the wrapper and extending generally peripherally about the wrapper adjacent to one of the top edge or the bottom edge. The casing further includes a cover coupled to the wrapper at one of the top edge or the bottom edge, the cover including a sidewall, the sidewall generally surrounding the channel. The casing further includes a fastener extending through the sidewall and the channel, the fastener coupling the wrapper and the cover together.

In accordance with another embodiment, a casing for a water heater appliance is provided. The casing includes a wrapper extending generally along a vertical direction between a top edge and a bottom edge, the wrapper including an inner surface and an outer surface and defining an interior of the casing. The casing further includes a channel defined in the outer surface of the wrapper and extending generally peripherally about the wrapper adjacent to one of the top edge or the bottom edge. The casing further includes a cover coupled to the wrapper at one of the top edge or the bottom edge, the cover including a sidewall, the sidewall generally surrounding the channel. The casing further includes a fastener extending through the sidewall and the channel, the fastener coupling the wrapper and the cover together.

In accordance with another embodiment, a method for assembling a casing for a water heater appliance is provided. The method includes positioning one of a top edge or a bottom edge of a wrapper within a cover, the wrapper including an inner surface and an outer surface and defining an interior, the cover including a base wall and a sidewall extending from the base wall. The method further includes providing a fastener through a bore hole in the sidewall such that the fastener contacts a channel wall of the wrapper, the channel wall defining a channel in the outer surface of the wrapper, the channel extending generally peripherally about the wrapper adjacent to the one of the top edge or the bottom edge. The method further includes traversing the fastener along the channel wall towards an apex of the channel if the fastener initially contacts the channel wall at a location spaced from the apex. The method further includes penetrating the channel generally through the apex with the fastener.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a water heater appliance in accordance with one embodiment of the present disclosure.

FIG. 2 provides a side cross-sectional view of a portion of a water heater appliance in accordance with one embodiment of the present disclosure.

FIG. 3 provides a side cross-sectional view of a portion of a casing of a water heater appliance, including a wrapper and bottom cover of the casing, prior to assembly of the casing in accordance with one embodiment of the present disclosure.

FIG. 4 provides a side cross-sectional view of a portion of a casing of a water heater appliance, including a wrapper and bottom cover of the casing, during an initial step of assembling the casing in accordance with one embodiment of the present disclosure.

FIG. 5 provides another side cross-sectional view of a portion of a casing of a water heater appliance, including a wrapper and bottom cover of the casing, during a subsequent step of assembling the casing in accordance with one embodiment of the present disclosure.

FIG. 6 provides another side cross-sectional view of a portion of a casing of a water heater appliance, including a wrapper and bottom cover of the casing, during another subsequent step of assembling the casing in accordance with one embodiment of the present disclosure.

FIG. 7 provides another side cross-sectional view of a portion of a casing of a water heater appliance, including a wrapper and bottom cover of the casing, after assembly of the casing in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 provides a perspective view of a water heater appliance 100 according to an exemplary embodiment of the present subject matter. Water heater appliance 100 includes a casing 102. A tank 101 (FIG. 2) and heating elements 103 (FIG. 2) are positioned within casing 102 for heating water therein. Heating elements 103 may include a gas burner, a heat pump, an electric resistance element, a microwave element, an induction element, or any other suitable heating element or combination thereof. As will be understood by those skilled in the art and as used herein, the term “water” includes purified water and solutions or mixtures containing water and, e.g., elements (such as calcium, chlorine, and fluorine), salts, bacteria, nitrates, organics, and other chemical compounds or substances.

Water heater appliance 100 also includes a cold water conduit 104 and a hot water conduit 106 that are both in fluid communication with a chamber 111 (FIG. 2) defined by tank 101. As an example, cold water from a water source, e.g., a municipal water supply or a well, can enter water heater appliance 100 through cold water conduit 104 (shown schematically with arrow labeled F_(cold) in FIG. 2). From cold water conduit 104, such cold water can enter chamber 111 of tank 101 wherein it is heated with heating elements 103 to generate heated water. Such heated water can exit water heater appliance 100 at hot water conduit 106 (shown schematically with arrow labeled F_(hot) in FIG. 2) and, e.g., be supplied to a bath, shower, sink, or any other suitable feature.

Water heater appliance 100 extends longitudinally between a top portion 108 and a bottom portion 109 along a vertical direction V. Thus, water heater appliance 100 is generally vertically oriented. Water heater appliance 100 can be leveled, e.g., such that casing 102 is plumb in the vertical direction V, in order to facilitate proper operation of water heater appliance 100. A drain pan 110 is positioned at bottom portion 109 of water heater appliance 100 such that water heater appliance 100 sits on drain pan 110. Drain pan 110 sits beneath water heater appliance 100 along the vertical direction V, e.g., to collect water that leaks from water heater appliance 100 or water that condenses on an evaporator (not shown) of water heater appliance 100. It should be understood that water heater appliance 100 is provided by way of example only and that the present subject matter may be used with any suitable water heater appliance, including for example a heat pump water heater appliance.

Referring to FIG. 2, water heater appliance 100 may further include a controller 134 that is configured for regulating operation of water heater appliance 100. Controller 134 may be in operative communication with various components of the water heater appliances, including, for example, heating elements 103, temperature sensors (not shown), and a control panel 107 (see FIG. 1). Control panel 107 may include various displays and input controls for user interface with the appliance 100. Controller 134 can, for example, selectively activate heating elements 103 in order to heat water within chamber 102 of tank 101.

Controller 134 includes memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of water heater appliance 100. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, controller 134 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

Referring now to FIGS. 1 through 7, casing 102 generally surrounds the tank 101, and may be formed from a variety of components. As illustrated, casing 102 may include a wrapper 150 and one or more covers, such as a top cover 152 and a bottom cover 154 as illustrated. The covers may be coupled to the wrapper 150 to form the casing 102.

Wrapper 150 extends generally along the vertical direction V between a top edge 156 and a bottom edge 158. When assembled, the top edge 156 may for example be proximate top portion 108 of the appliance 100, and the bottom edge 158 may for example be proximate bottom portion 109 of the appliance 100. The wrapper 150 may be a generally tubular, hollow component, and in exemplary embodiments may be generally cylindrical. An interior 160 of the casing 102 may be at least partially defined by the wrapper 150, such as by an inner surface 162 of the wrapper 150. An outer surface 164 of the wrapper 150 may be opposite the inner surface 162.

As illustrated in FIGS. 2 through 7, one or more channels 170 may be defined in the wrapper 150, such as in the outer surface 164 thereof. Each channel 170 may extend generally peripherally about the wrapper 150, such as circumferentially about the wrapper 150 in the case of, for example, cylindrical wrappers 150. Each channel 170 may advantageously be configured to facilitate alignment of a cover, such as a top cover 152 or a bottom cover 154, with the wrapper 150. For example, the shape and location of the channel 170 may assist in the locating and orienting of fasteners utilized to couple a cover to the wrapper 150. Such locating and orienting of the fasteners may cause the cover to accurately align with the wrapper 150, thus reducing or eliminating misalignments between with wrapper 150 and the cover.

Each channel 170 may be defined adjacent to the top edge 156 or the bottom edge 158 of the wrapper 150. Accordingly, as discussed below, when a cover is coupled to the wrapper 150, a portion of the cover may overlap and generally surround the channel 170.

As illustrated, a channel 170 in exemplary embodiments may be generally V-shaped (when viewed in cross-section). For example, the wrapper 150 may include a plurality of channel walls 172 that may define the channel 170 therebetween. In some embodiments, two generally linear walls 172 may taper towards each other to form a V-shaped channel 170. The channel walls 172 may for example, define a channel angle 174 therebetween. The channel angle 174 may in some embodiments be between approximately 90 degrees and approximately 150 degrees, such as between approximately 105 degrees and approximately 135 degrees, such as approximately 120 degrees.

Alternatively, the walls 172 may be curvilinear, such that for example, a generally U-shaped channel 170 is formed. In still other embodiments, a channel 170 may have any suitable shape (when viewed in cross-section). In exemplary embodiments, a suitable channel 170 in accordance with the present disclosure may have a generally tapered shape.

In some embodiments as further illustrated, a wrapper 150 may include a body portion 180 and one or more shelf portions 182. The portions 180, 182 may each be generally peripheral portions of the wrapper 150, and may be distinguished generally along the vertical direction V. A shelf portion 182 may extend generally between the top edge 156 or bottom edge 158 and the body portion 180. The body portion 180 may have a perimeter that is greater than the perimeter of each shelf portion 182. The difference in perimeters between the body portion 180 and a shelf portion 182 may cause a shelf 184 to be formed between the body portion 180 and that shelf portion 182, as illustrated.

In exemplary embodiments, a channel 170 may be formed in a shelf portion 182. For example, FIG. 2 illustrates a shelf portion 182 extending from the top edge 156, while FIGS. 3 through 7 illustrate a shelf portion 182 extending from the bottom edge 158. A channel 170 may be defined in each shelf portion 182. The channel 170 defined adjacent to the top edge 156 is illustrated in FIG. 2, while the channel 170 defined adjacent to the bottom edge 158 is illustrated in FIGS. 3 through 7.

The use of channels 170 defined in the wrapper 150 as disclosed herein may advantageously facilitate the alignment of the associated covers 152, 154 with the wrapper 150. As mentioned, a casing 102 further includes one or more covers, such as a top cover 152 and a bottom cover 154. Each cover 152, 154 may be coupled to the wrapper 150 at the top edge 156 or the bottom edge 158. Further, a portion of a cover may, when a channel 170 is defined adjacent to the edge 156, 158 with which the cover is associated, generally surround that channel 170. For example, a cover 152, 154 may include a base wall 190 and a sidewall 192. The sidewall 192 may extend from the base wall 190, such as generally along the vertical direction V when the casing 102 and appliance 100 are assembled. The sidewall 192 may be a generally peripheral wall having a peripheral shape that generally conforms with the peripheral shape of the wrapper 150. In exemplary embodiments, for example, the sidewall 192 may be cylindrical. When assembled and when a channel 170 is defined adjacent to the edge 156, 158 with which the cover is associated, the sidewall 192 may generally surround the channel 170.

As stated, the top edge 156 and/or bottom edge 158 may thus be positioned and, when assembled, disposed within a cover 152, 154. It is particularly advantageous for the cover 152, 154 to generally surround the top edge 156 and/or bottom edge 158, and thus be located outside of the top edge 156 and/or bottom edge 158. Such assembly, for example, may generally prevent leakage of sealant (discussed herein), may cover sharp edges of the wrapper 150, and may facilitate ease of assembly of the casing 102 and water heater appliance 100 generally.

Further, one or more fasteners 195 may couple the wrapper 150 and the cover(s) 152, 154 together. Any suitable fastener, such as a nail, screw, bolt, rivet, etc., may be utilized. Each fastener 195 may extend through the sidewall 192 of a cover 152, 154, such as through a bore hole 197 defined therein. Each fastener 195 may further, when a channel 170 is defined adjacent to the edge 156, 158 with which the cover is associated, extend through the channel 170. Notably, in exemplary embodiments, a fastener 195 may extend through an apex 199 of the channel 170. As discussed herein, when the fastener 195 initially contacts one of the channel walls 172 defining the channel 170, the associated cover 152, 154 may be misaligned with the wrapper 150, as illustrated in FIG. 4. The shape of the channel 170 and the channel walls 172, and in particular the taper of the walls 172, may cause the fastener 195 to traverse along the initially contacted wall to, for example, an apex 199 of the channel 170, as illustrated in FIG. 5. Such traversal may cause the cover 152, 154 and wrapper 150 to align. The channel 170, such as the channel walls 172 thereof, may then be penetrated by the fastener 195 through the apex 199, as illustrated in FIG. 6.

The present disclosure is further directed to methods for assembling a casing 102 for a water heater appliance 100. A method may include, for example, the step of positioning one or both of a top edge 156 or a bottom edge 158 of a wrapper 150 within a cover or covers, such as a top cover 152 and/or a bottom cover 154. FIG. 3 illustrates a wrapper 150 and cover before an edge of the wrapper 150 is positioned within the cover. FIG. 4 illustrates a wrapper 150 and cover with an edge of the wrapper 150 positioned within the cover.

A method may further include the step of providing a fastener 195 through a bore hole 197 in the sidewall 192 of the cover such that the fastener 195 contacts a channel wall 172 of the wrapper 150, as illustrated in FIG. 4. As discussed, the channel wall 172 may defined a channel 170 in the outer surface 164 of the wrapper 150.

Notably, the fastener may initially contact the channel wall 172 at a location spaced from an apex 199 of the channel 170, as illustrated in FIG. 4. If this occurs, the cover 152, 154 and wrapper 150 may be misaligned. Accordingly, a method may further include the step of traversing the fastener 195 along the channel wall 172 towards the apex 199 of the channel 170 if the fastener 195 initially contacts the channel wall 172 at a location spaced from the apex 199. The resulting position of the fastener 195 in contact and/or aligned with the apex 199 is illustrated in FIG. 5. Such traversal to contact and align with the apex 199 may cause relative movement of the cover 152, 154 and wrapper 150 such that they are properly aligned.

A method may further include, for example, penetrating the channel 170 generally through the apex 199 with the fastener 195, as illustrated in FIG. 6. Such penetration may result in coupling of the cover 152, 154 and the wrapper 150. Further, due to the interaction between the channel 170 and fastener 195, the coupled together cover 152, 154 and wrapper 150 may be properly aligned relative to each other.

In some embodiments, a method may further include, for example, providing a sealant layer 200 between the sidewall 192 of one or more covers 152, 154 and the wrapper 150. FIG. 7 illustrates a sealant layer 200 disposed between the sidewall 192 and the wrapper 150. The sealant layer 200 may provide a seal between the components, further coupling them together and improving the efficiency of the resulting appliance 100. For example, the sealant may serve to insulate the tank 101. In exemplary embodiments, for example, the sealant layer 200 may be a foam, such as a foam insulation.

Accordingly, the present disclosure provides improved casings 102 and methods for assembling casings 102 for water heater appliances 100. As discussed herein, channels 170 defined in the wrappers 150 of such casings 102 may interact with the covers 152, 154 of the casings 102 to advantageously facilitate improved alignment of the wrappers 150 and covers 152, 154 relative to each other. Such improved alignment can provide a variety of advantages. For example, improved alignment can result in reduced potential for compromised components during use, consistent sealing material thicknesses, reduced inefficiencies and performance losses, improved alignments with other water heater appliance components or external components such as inlet and outlet pipes, and improved height and appearance consistencies.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A water heater appliance, comprising: a tank defining a chamber; a casing generally surrounding the tank, the casing comprising: a wrapper extending generally along a vertical direction between a top edge and a bottom edge, the wrapper comprising an inner surface and an outer surface and defining an interior of the casing; a channel defined in the outer surface of the wrapper and extending generally peripherally about the wrapper adjacent to one of the top edge or the bottom edge; a cover coupled to the wrapper at one of the top edge or the bottom edge, the cover comprising a sidewall, the sidewall generally surrounding the channel; and a fastener extending through the sidewall and the channel, the fastener coupling the wrapper and the cover together.
 2. The water heater appliance of claim 1, wherein the channel is generally V-shaped.
 3. The water heat appliance of claim 1, wherein the wrapper comprises a plurality of channel walls defining the channels, and wherein the channel walls define a channel angle therebetween, the channel angle between approximately 90 degrees and approximately 150 degrees.
 4. The water heater appliance of claim 1, wherein the wrapper comprises a body portion and a shelf portion, the shelf portion extending generally vertically between one of the top edge or the bottom edge and the body portion, the body portion having a perimeter greater than a perimeter of the shelf portion.
 5. The water heater appliance of claim 4, wherein the channel is defined in the shelf portion.
 6. The water heater appliance of claim 1, wherein the casing further comprises a sealant layer disposed between the sidewall of the cover and the wrapper.
 7. The water heater appliance of claim 1, wherein the wrapper is generally cylindrical.
 8. The water heater appliance of claim 1, wherein the cover is a top cover and the channel is defined adjacent to the top edge.
 9. The water heater appliance of claim 1, wherein the cover is a bottom cover and the channel is defined adjacent to the bottom edge.
 10. The water heater appliance of claim 1, wherein the channel is a plurality of channels, each of the plurality of channels disposed adjacent to one of the top edge or the bottom edge.
 11. The water heater appliance of claim 1, wherein the cover is a plurality of covers.
 12. A casing for a water heater appliance, the casing comprising: a wrapper extending generally along a vertical direction between a top edge and a bottom edge, the wrapper comprising an inner surface and an outer surface and defining an interior of the casing; a channel defined in the outer surface of the wrapper and extending generally peripherally about the wrapper adjacent to one of the top edge or the bottom edge; a cover coupled to the wrapper at one of the top edge or the bottom edge, the cover comprising a sidewall, the sidewall generally surrounding the channel; and a fastener extending through the sidewall and the channel, the fastener coupling the wrapper and the cover together.
 13. The casing of claim 12, wherein the channel is generally V-shaped.
 14. The casing of claim 12, wherein the wrapper comprises a body portion and a shelf portion, the shelf portion extending generally vertically between one of the top edge or the bottom edge and the body portion, the body portion having a perimeter greater than a perimeter of the shelf portion.
 15. The casing of claim 12, wherein the wrapper is generally cylindrical.
 16. The casing of claim 12, wherein the cover is a top cover and the channel is defined adjacent to the top edge.
 17. The casing of claim 12, wherein the cover is a bottom cover and the channel is defined adjacent to the bottom edge.
 18. A method for assembling a casing for a water heater appliance, the method comprising: positioning one of a top edge or a bottom edge of a wrapper within a cover, the wrapper comprising an inner surface and an outer surface and defining an interior, the cover comprising a base wall and a sidewall extending from the base wall; providing a fastener through a bore hole in the sidewall such that the fastener contacts a channel wall of the wrapper, the channel wall defining a channel in the outer surface of the wrapper, the channel extending generally peripherally about the wrapper adjacent to the one of the top edge or the bottom edge; traversing the fastener along the channel wall towards an apex of the channel if the fastener initially contacts the channel wall at a location spaced from the apex; and penetrating the channel generally through the apex with the fastener.
 19. The method of claim 18, wherein the channel is generally V-shaped.
 20. The method of claim 18, wherein the wrapper is generally cylindrical. 